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Joule Cyclone Domestic Cylinders Installation Manual
Joule Cyclone Domestic Cylinders Installation Manual
Joule Cyclone Domestic Cylinders Installation Manual
IRELAND
www.joule.ie/register-a-product
UNITED KINGDOM
JL-CYDID-INS-009-11-2017 www.jouleuk.co.uk/register-a-product
Cyclone Direct / Indirect Installation Guide 1
Warranty Card MUST BE COMPLETED AND
Please register your product online THEN REGISTERED ONLINE
TO COMPLETE WARRANTY
Homeowner Installer
Name Name
Address Address
Cylinder Located on
cylinder badge
Was a Pre-Plumbed If installed, please fill out the Heat Pump Commissioning
cylinder installed too? Sheet too
2 www.jouleuk.co.uk | www.joule.ie
Joule™ Product Warranty Terms & Conditions
Please note that invoices for servicing may be Warning To The Installer
requested to prove that the unit has been ser-
• Read the installation instructions before
viced annually.
commencing.
Joule™ fully endorse the Benchmark scheme
• Unvented water heaters are a controlled
and the code of practice can be obtained from
service as defined in the latest edition of
www.centralheating.co.uk
the Building Regulations and should only
be fitted by a competent installer.
• The installation is subject to approval.
• You must notify the local authority of inten-
tion to install.
• After installation the instructions manual
must be completed and left with the house-
holder.
• Use only manufacturer’s recommended re-
placement parts.
Installed by
Installer
Name
Address
Contact Tel.
Completion
Date
4 www.jouleuk.co.uk | www.joule.ie
Table Of Contents
6 Introduction
10 General Requirements
14 Unvented Kit Components
15 Unvented Kit Checklist
16 ErP Product Fiche
17 Technical Data
18 Indirect Vertical Technical Specification
20 Indirect High Gain Technical Specification
22 Solar High Gain Technical Specification
24 Direct Vertical Technical Specification
26 Solar Vertical Technical Specification
28 Direct Horizontal Specification
29 Indirect Horizontal Specification
30 Plumbing G3 Unvented Kit NEW
31 Testing
32 Smart Control Immersion Setup
33 Immersion Testing
36 Un-Plumbed Cylinder Schematic S-Plan
38 Un-Plumbed Cylinder Schematic Y-Plan
40 Pre-Plumbed Cylinder Schematic - System Boiler, 1 Heating Zone
42 Pre-Plumbed Cylinder Schematic - System Boiler, 2 Heating Zone
44 Pre-Plumbed Cylinder Schematic - Heat Only Boiler, 1 Heating Zone
46 Pre-Plumbed Cylinder Schematic - Heat Only Boiler, 2 Heating Zone
48 Electronic Controls
49 Discharge Arrangement
52 Commissioning
53 Maintenance
55 Taking The Cylinder Out Of Use
56 Troubleshooting
58 Benchmark Checklist
60 Service Record
61 Notes
The instructions are an integral part of the appliance and must be given to the end user on comple-
tion of the installation in order to comply with the current regulation.
It is important to carefully read the manual to understand all the information to enable safe installa-
tion, use and servicing. These instructions consist of details for installation, servicing, fault finding
and replacement of parts for the cylinder purchased.
Joule™ will not accept any liability in the event of damage for not complying with the guidance in
this instruction manual.
The instructions for this installation manual apply to the range of Joule™ Cyclone Unvented Cylinders.
Safety is paramount when installing unvented hot water systems and the following instructions must
be adhered to:
• Only certified competant installers can install, commission and service the equipment supplied.
• The cylinder must be used for potable hot water only. Any other applications will be considered
incorrect use and Joule™ will not be held liable for any losses resulting from such use.
• All installation and maintenance instructions must be observed to ensure the correct operation
of the equipment.
• The electric immersion must not be switched on unless the cylinder is completely full of water.
• Domestic hot water may be stored at temperatures exceeding 60°C. Preventative measures
should be put in place to negate the possibility of scalding.
• A maintenance schedule should be put in place with a competent person to service the equip-
ment annually to comply with the warranty conditions.
• When servicing the system the mains supply to the cylinder should be isolated.
• Only genuine spare parts should be used. A full list of items with relevant codes can be found
on page 14.
The installation must be carried out by a person competent to install unvented hot water systems.
The installation must be carried out in accordance with the following recommendations:
All current Building Regulations issued by the Department of the Environment, i.e. Building Regula-
tion G3 (England and Wales), Technical Standard P3 (Scotland) or Building Regulation P5 (Northern
Ireland) and the Water Fitting Regulations (England and Wales) or Water Byelaws (Scotland). The
installation should also be in accordance with the following British Standard Codes of Practice:
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Handling
Care must be taken when transporting, storing and installing the equipment:
• At least two people should lift the cylinder to prevent injuries.
• The cylinder must be stored in a dry area and must never be dropped during handling.
• Packaging should only be removed at the installation location.
• The cylinder must be installed on a level floor with the required load bearing capability. Installa-
tion, servicing, maintenance and repair must be carried out by a competent person.
• All electrical wiring must be carried out by a qualified electrician and be installed in accordance
with current I.E.E Wiring Regulations.
• A lack of safety devices can lead to potentially fatal injuries, all necessary safety devices must
be installed correctly in the system. The use of an electric immersion may lead to the build up
of electrical potential in the water. This can in turn cause corrosion of the immersion. To prevent
this, ensure the immersion heater, and the hot and cold pipework are correctly bonded and
connected to the earth line.
• If plastic pipes are used they must be approved temperature resistant to 95°C at a pressure of
10bar.
A thermostatic mixer should be installed in the system to prevent the risk of scalding. If there are
leaks found in the system, shut off the cold water stop valve from the main supply and contact a
competent person immediately. Also ensure to isolate the power going to any immersions fitted to
the cylinder
What Is Benchmark?
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure
that customers are provided with the correct equipment for their needs, that it is installed, commis-
sioned and serviced in accordance with the manufacturer’s instructions by competent persons and
that it meets the requirements of the appropriate Building Regulations.
The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and
should be provided to the customer for future reference. Installers are required to carry out installa-
tion, commissioning and servicing work in accordance with the Benchmark Code of Practice which
is available from the Heating and Hot Water Industry Council who manage and promote the scheme.
Visit www.centralheating.co.uk
Water Supply
The performance of any unvented system is only as good as the mains water supply available. To
this effect the maximum possible water demand should be assessed, with the knowledge that the
mains supplies both hot and cold services simultaneously. The water heater itself operates at a
pressure of 3bar, controlled by the inlet control set, and is capable of delivering over 50 litres per minute.
The high quality inlet control set has been designed to make the most of the low rates available.
The water supply should be checked to ensure it can meet these requirements. If necessary, consult
the local water authority regarding the likely pressure and flow rate availability.
Consideration should be given to upgrading existing 1⁄2” (15mm) cold mains pipework to a larger
size if the recommended minimum pressure / flow rate is not being achieved. Joule™ recommend
that primary pipework used has a minimum diameter of 22mm to ensure low pressure loss.
A high static (no flow) mains pressure is no guarantee of good flow availability. In a
domestic installation 1.5bar and 25ltr/min should be regarded as the minimum. The
maximum mains pressure that the inlet control set can cope with is 10bar.
Water Chemistry
This water heater must be installed in accordance with this advice to be covered by the Joule™ war-
ranty. This water heater is manufactured to suit the water conditions of most public reticulated water
supplies. However, there are some known water chemistries which can have detrimental effects on
the water heater and its operation and/or life expectancy. If you are unsure of your water chemistry,
you may be able to obtain information from your local water supply authority.
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Water Chemistry Levels Affecting Warranty
The Joule™ warranty of this water heater will not cover resultant faults on components including the
storage cylinder where water stored in the storage cylinder exceeds at any time any of the following
levels:
Magnesium 10 mg/litre
Calcium 20 mg/litre
Iron 1 mg/litre
Maximum pH 9.5
Minimum pH 6.5
Wellmaster Cylinders
Only Joule™ Wellmaster cylinders may be installed on a well, private water scheme or any water
source that does not come from the public mains.
Water supplied to the cylinder must conform to the water chemistry table on the previous page. A
descaler on the cold water feed may be used if required.
If any of the water parameters are higher than set out in the table including total
hardness regardless of wheter or not it is fed from a main water connection a Joule™
Wellmaster cylinder must be used.
If any of the water parameters are higher than set out in the table including Total Hardness regardless
of whether or not it is fed from a main water connection a Joule™ Wellmaster cylinder must be used.
Sufficient access to allow maintenance of the valves should be considered. In addition the immer-
sion heaters are 400mm in length and this distance should be considered to allow withdrawal for
servicing if required. The discharge pipework from the safety valves should fall continuously and
terminate safely.
Negative pressure may form in cylinders installed very high in a building. To counteract this, an an-
ti-vacuum valve can be installed to prevent damage to the cylinder. The anti-vacuum valve ensures
pressure compensation as a result of air flowing into the cylinder.
No control or isolation valve should be fitted between the expansion relief valve and the
storage cylinder. The relief valve connections should not be used for any other purpose.
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Cold Mains Pipework
Run the cold main through the building to the place where is to be installed. Take care not to run the
cold pipe near hot water or heating pipe work so that the heat pick-up is minimized. Identify the cold
water supply pipe and fit an isolating valve (not supplied). A 22mm BS1010 stopcock can typically
be used but a 22mm quarter turn full bore valve would be better as it does not restrict the flow as
much. Do not use “screwdriver slot” or similar valves.
Make the connection to the cold feed of the cylinder and incorporate a drain valve. Position the
inlet control just above the Temperature & Pressure Relief Valve (TPRV) mounted on the side of the
cylinder. This ensures that the cylinder does not have to be drained down in order to service the inlet
control set. Ensure that the arrow points in the direction of the water flow. Select a suitable position
for the expansion vessel. Mount it to the wall using the bracket provided.
Expansion Vessel
The expansion vessel receives the increased water volume when expansion takes place as the
system heats up and it maintains a positive pressure in the system. The expansion vessel contains
a flexible diaphragm, which is initially charged on one side with nitrogen, but can be topped up with
air when required.
Select a suitable position for the expansion vessel. Mount it to the wall using the bracket provided
(0-24L only, 35L and above are floor standing) and hard fix into pipework and insulate. Ensure that
the top of the vessel is accessible for servicing. The pipe connecting the expansion vessel to the
system should have a diameter of not less than 15mm and must not contain any restrictions.
Prior to connecting the expansion vessel to the system the pipework should be flushed and tested.
When the vessel is connected the system should be pressurised when cold. If the initial system
water pressure is too high, the diaphragm will be displaced too far into the vessel. This will leave the
vessel unable to accommodate the volume of expansion water. The result of this is an increase in
system pressure and the safety valve will lift.
The boiler may be Gas, Electric or Oil but must be under effective thermostatic control. Uncontrolled
heat sources such as some AGA’s, back boilers, solid fuel stoves, etc. are not suitable. Please con-
tact our Technical department for guidance. Connect the two port zone valve (indirect only) into the
primary flow pipework. The direction of flow arrow should be towards the primary flow connection.
Thermostatic Mixer
When installing a solar system with an unvented Joule™ Cyclone twin coil cylinder, a thermostatic
mixing valve should be installed. Its function is to act as an anti scald protection. The thermostatic
mixer is to be set to a temperature of between 30°C and 60°C and is supplied by the installer.
Secondary Circulation
On larger installations long pipe runs to draw-off points can cause significant volumes of water to be
drawn off before an acceptable temperature can be reached. Secondary pumped circulation using
a stainless steel or a bronze pump, and combined with effective time and temperature controls can
overcome this problem. Where secondary return circulation is required the pipework should be run
in 15mm pipe. A suitable WRAS approved stainless steel or bronze circulation pump must be used.
A check valve must also be installed to prevent back flow.
On large secondary circulation systems it may be necessary to incorporate an extra expansion
vessel into the circuit to accommodate the increased system water volume. Secondary circulation
should be avoided on Direct electrically heated units being used on off-peak electricity tariffs. It
should be noted that the use of a secondary circulation circuit can increase running costs as there
will be circulation pipe losses. High levels of insulation on secondary pipework are required to keep
energy losses to a minimum.
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Dead Legs
The length of hot water draw off to taps and other outlets should be kept to a minimum to reduce
the amount of cold water drawn off before the hot water arrives. The maximum recommended dead
leg lengths are shown in the table below. Where there is more than one size of pipe on a dead leg,
the equivalent length and size should be estimated. Where the dead leg length exceeds the rec-
ommended maximum, secondary circulation should be installed. It should be controlled by a time
switch and incorporate a motorized valve that can prevent gravity circulation in the circuit.
Pipe Size (mm) Maximum Length (m)
10, 12 20
15, 22 12
28 8
35 and above 3
System Noise
Noise in pipework may occur as a result of expansion of pipework over joists or where the pipe has
been left touching other pipes or a part of the building structure. Care must be taken to ensure that
the pipework is correctly bracketed, is not in tension or compression, and does not carry the weight
of components such as a circulation pump.
Inappropriate adjustments can lead to the damages in the system. If any changes are
made to the cylinder, the controls, the water and power supply lines or the expansion
relief components there is a risk of steam escaping or rupture to the system.
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Unvented Kit Checklist
Direct, Indirect & Solar
Capacity (ltr) 100 125 150 170 200 250 300 400 500
TZG-3.0-
Inlet Group TZG-3.0-0.75L
0001L
TV-P- TV-P- TV-P-
Expansion Vessel TV-P-000019L
000024L 000035L 000050L
T&P Valve TZ9-4.0-0000.5 TZ9-4.0-000.75
TZU-0000
Tundish TZU-000015X22
022X1
Dual Stat TZC-D-000000Z
Nominal Capacity (ltr) 100 125 150 170 200 250 300 400 500
Direct Vertical
Storage volume V (ltr) 99 127 150 169 200 250 294 - -
Mixed water at 40°C (ltr) 149 191 225 254 300 377 441 - -
The declared load profile L L L L L L XL - -
ErP Rating C C C C C C D - -
Energy Efficiency (%) 39 39 38 38 38 37 37 - -
Ann. el. consumption (kWh) 2650 2654 2715 2719 2723 2764 4508 - -
Sound Power Level (dB) 16 16 16 16 16 16 16 - -
Thermostat Temp. Set. (°C) 60 60 60 60 60 60 60 - -
Daily En. Usage Qelec
12.189 12.213 12.577 12.601 12.625 12.868 20.962 - -
(kWh/24h)
Nominal Capacity (ltr) 100 125 150 170 200 250 300 400 500
Direct Horizontal
Storage volume V in ltr 99 127 150 169 200 250 294 - -
Mixed water at 40°C (ltr) 149 191 225 254 300 377 441 - -
The declared load profile L L L L L L XL - -
ErP Rating C C C C C C D - -
Energy Efficiency (%) 39 39 38 38 38 37 37 - -
Ann. el. consumption (kWh) 2650 2654 2715 2719 2723 2764 4508 - -
Sound Power Level (dB) 16 16 16 16 16 16 16 - -
Thermostat Temp. Set. (°C) 60 60 60 60 60 60 60 - -
Daily En. Usage Qelec
12.189 12.213 12.577 12.601 12.625 12.868 20.962 - -
(kWh/24h)
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Nominal Capacity (ltr) 100 125 150 170 200 250 300 400 500
Indirect & Solar Vertical
Storage Volume V (ltr) 96 124 147 168 194 247 290 390 495
Standing Loss (kW) 44 52 55 58 78 87 92 102 115
ErP Rating B B B B C C C C C
Nominal Capacity (ltr) 100 125 150 170 200 250 300 400 500
Indirect & Solar Horizontal
Storage Volume V (ltr) - - 147 168 194 247 290 - -
Standing Loss (kW) - - 57 60 80 89 94 - -
ErP Rating - - C C C C C - -
Technical Data
Indirect models in conformance with BS EN 12897:2016
14
H
13
G
10
A
9
8
F
E
9 3
7
D 15º
30º 30º
C C
2 3
2 Boiler Return
3 Cold Water Inlet
7 Aquastat Pocket
8 Boiler Flow
9 Incoloy Immersion (fact. fitted)
10 Secondary Return
13 T&P Relief Valve
14 Hot Water Draw Off
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Connection Sizes & Safety 100 125 150 170 200 250 300 400 500
Hot & Cold Conn. Ø (mm) 22 22 22 22 22 22 22 28 28
Coil Connection Ø (mm) 22 22 22 22 22 22 22 22 22
Secondary Return Ø BSP F (“) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
T&P Connection Ø BSP F (“) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.75 0.75
T&P Press. Set. (bar) 7 7 7 7 7 7 7 7 7
3bar
Exp. Relief Set. (bar) 6 6 6 6 6 6 6 6 6
Dimensions 100 125 150 170 200 250 300 400 500
Cylinder Height (A, mm) 950 1030 1190 1310 1490 1815 1600 1570 1900
Cylinder Diameter (B, mm) 500 540 540 540 540 540 600 710 710
Connection Height C (mm) 188 196 196 196 196 196 218 225 225
Connection Height D (mm) 333 211 341 341 341 361 383 405 455
Connection Height E (mm) 478 511 486 486 516 586 608 675 745
Connection Height F (mm) 543 651 651 651 581 651 673 740 810
Connection Height G (mm) 628 751 786 881 981 1271 1153 1180 1440
Connection Height H (mm) 743 800 911 1031 1211 1531 1333 1280 1640
Performance 100 125 150 170 200 250 300 400 500
14
7
H
13
I 10
F
8
7
E 7
9 3
3
D
15º
G 9
30º 30º
C
2
2 Primary Return
3 Cold Water Inlet
7 Aquastat Pocket
8 Primary Flow
9 Incoloy Immersion (fact. fitted)
10 Secondary Return
13 T&P Relief Valve
14 Hot Water Draw Off
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Connection Sizes & Safety 100 125 150 170 200 250 300 400 500
Hot & Cold Conn. Ø (mm) - - 28 28 28 28 28 28 28
Coil Connection Ø (mm) - - 28 28 28 28 28 28 28
Secondary Return Ø BSP F (“) - - 0.5 0.5 0.5 0.5 0.5 0.5 0.5
T&P Connection Ø BSP F (“) - - 0.5 0.5 0.5 0.5 0.5 0.75 0.75
T&P Press. Set. (bar) - - 7 7 7 7 7 7 7
3bar
Exp. Relief Set. (bar) - - 6 6 6 6 6 6 6
Dimensions 100 125 150 170 200 250 300 400 500
Cylinder Height (A, mm) - - 1190 1310 1490 1815 1600 1570 1900
Cylinder Diameter (B, mm) - - 540 540 540 540 600 710 710
Connection Height C (mm) - - 196 196 196 196 218 226 225
Connection Height D (mm) - - 346 346 346 346 368 376 375
Connection Height E (mm) - - 420 420 420 450 450 470 480
Connection Height F (mm) - - 766 806 946 1046 1018 1176 1225
Connection Height G (mm) - - 346 346 346 346 368 376 375
Connection Height H (mm) - - 870 1030 1211 1531 1333 1281 1640
Connection Height I (mm) - - 820 881 981 1271 1153 1191 1440
14
15
L L
13
10
K
J
8
7
A I
2
9 H
G 10 3
F
7
E 16
15 30º 30º
D
C C
17 3
2 Primary Return
3 Cold Water Inlet
7 Aquastat Pocket
8 Primary Flow
9 Incoloy Immersion (fact. fitted)
10 Secondary Return
13 T&P Relief Valve
14 Hot Water Draw Off
15 Solar Sensor
16 Solar / Boiler Flow
17 Solar / Boiler Return
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Connection Sizes & Safety 170 200 250 300 400 500
14
G
13
F
10
A
10 3
9
E
30º 30º
D C
15 3
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Connection Sizes & Safety 100 125 150 170 200 250 300
Hot & Cold Conn. Ø (mm) 22 22 22 22 22 22 22
Coil Connection Ø (mm) 22 22 22 22 22 22 22
Secondary Return Ø BSP F (“) 0.5 0.5 0.5 0.5 0.5 0.5 0.5
T&P Connection Ø BSP F (“) 0.5 0.5 0.5 0.5 0.5 0.5 0.5
T&P Press. Set. (bar) 7 7 7 7 7 7 7
3bar
Exp. Relief Set. (bar) 6 6 6 6 6 6 6
14
15
L L
13
10
K
J
8
7
A I
2
9 H
G 10 3
F
7
E 16
15 30º 30º
D
C C
17 3
2 Boiler Return
3 Cold Water Inlet
7 Aquastat Pocket
8 Boiler Flow
9 Incoloy Immersion (fact. fitted)
10 Secondary Return
13 T&P Relief Valve
14 Hot Water Draw Off
15 Solar Sensor
16 Solar / Boiler Flow
17 Solar / Boiler Return
26 www.jouleuk.co.uk | www.joule.ie
Connection Sizes & Safety 170 200 250 300 400 500
Secondary Return Ø BSP F (“) 0.5 0.5 0.5 0.5 0.5 0.5
T&P Connection Ø BSP F (“) 0.5 0.5 0.5 0.5 0.75 0.75
Cylinder Diameter (B, mm) 540 540 540 600 710 710
X Y
X Y
3 2
B
4
4 5
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Indirect Horizontal Technical Specification
A
X Y
X Y
3 2
6
B
4 7
5 8
Secondary Return
1 2 3
Failure to install unvented kit correctly invalidate warranty and does not comply with
Building Regulations.
30 www.jouleuk.co.uk | www.joule.ie
Testing
Do not connect a 6kW Immersion
without using a relay switch.
20 Amp Fused
2-pole Isolating Switch
230V AC ~50Hz
Standard Immersion
20 Amp Fused
2-pole Isolating Switch
230V AC ~50Hz
Smart Immersion
Do not operate the immersion heaters until the cylinder has been filled with water
Wire the immersion through a double pole fused spur. The contact separation must be no less than
3mm with a minimum breaking capacity of 16A.
• OFF
• ECO – smart control: starts for 2 weeks at 70°C and then it will select automatically storage
temperatures through the day
• MANUAL – works as standard mechanical thermostat can be set up to 70°C
• OPK (off peak) – this must be selected when the cylinder is connected to the night tariff. During
the day time the immersion is not connected and this would require the smart control to be reset.
When OPK is selected it should be set at 60°C and working as a standard thermostat. Alterna-
tively the user can select the manual mode.
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Immersion Installation
1. Check your mains power voltage matches the voltage rating indicated on the label of the plastic
terminal cover.
2. The immersion heater must be fixed to the cylinder using the gasket provided. Please ensure
that the unit is not over tightened into the tank boss. Silicon sealant on the gasket is recom-
mended.
This heater should only be installed in systems where the element is always below
water level, such as a cistern fed tank. Check that there is water in the tank before
the immersion heater is first switch on.
If the heater is allowed to run when the water level is not fully covering the heating element there may
be serious damage incurred to the heater, property or persons.
The appliance is not to be used by children or persons with reduced physical, sensory or mental
capabilities,orlackofexperienceand knowledge,unlesstheyhavebeengivensupervisionorinstruction
concerning use of the appliance by a person responsible for their safety. Children should be super-
vised to ensure that they do not play with the appliance.
Thermostat Information
The immersion heater is supplied with a T-MEC 2 Electronic thermostat. To maintain safety, any
thermostat replacement must be of the same type.
Low water temperature is recommended to reduce limestone deposit (not lower than 60ºC)
The thermostat in this unit is able to disconnect both supply conductors (live and neutral) by a single
initiating action. It has a safety resettable cut out mechanism which prevents excessive tempera-
tures. In case the normal sensing device fail, the over temperature safety device will act to limit the
water over-temperature.
3. Remove the cover and press the button on the top of the thermostat.
NB: This cut out is a safety device, if this is found to be operating frequently then we recommend to
consult a qualified electrician to investigate the nature of the problem as the thermostat may need to
be replaced. It may be helpful to lower the thermostat setting to avoid unnecessary cut offs.
tat.
Knob setting
tly then we recommend to consult position
rmostat may The Thermowatt
need to be replaced. TMEC-2 Electronic Thermostat has 5 operating modes, and is supplied set to
ut offs. the maximum control temperature of 70°C. To select the alternative modes the adjustment knob is
turned anticlockwise, until the slot in the adjustment knob is in line with the required mode:
odes, and is supplied set to the
es the adjustment knob is turned
quired mode:
y efficiency ECO – Smart mode Factory Setting – This setting gives maximum energy ef-
mperature ficiency and uses smart technology to learn the user’s habits to control water
70°C whilst temperature to suit demand. During the first week the thermostat will run at
ek it adjusts automatically to give 70°C whilst recording hot water usage, then the following and each subse-
quent week it adjusts automatically to give the most efficient use of electricity.
In the event of any power loss the thermostat will lose all recorded data, and
will restart learning mode. Antibacterial mode will function.
Changing thermostat setting from the factory pre-set position may impact upon the
thermostat will lose all recorded efficiency rating of the cylinder in which it is fitted.
OTE: Changing thermostat setting
of the cylinder in which it is fitted.
ned on this will lose all recorded
thermostat OPK – Basic Electronic Thermostat mode – With the control knob turned
60°C
OTE: and is willthermostat
Changing
thermostat setting
lose all recorded on this position the thermostat will control water temperature to maximum
or
of manual
the
OTE: cylinder inthermostat
Changing which it is setting
fitted. 60°C
the most and is unaffected
efficient by any
use of electricity. In theinterruption of power
event of any power loss thesupply.
thermostat Use
willthis
lose posi-
all recorded
mode
of the will
ned on this
function.
cylinder in which it is fitted. tion for
data, and manual
will switching
restart learning mode.orAntibacterial
by timer such
mode willas economy
function. NOTE:type installations.
Changing thermostat setting
e thermostat will lose all recorded Antibacterial modeposition
from the factory pre-set will function.
may impact upon the efficiency rating of the cylinder in which it is fitted.
e safety
60°C
ned and
on cutis
this
NOTE: Changing thermostat setting
or
60°C manual
and is OPK – Basic Electronic Thermostat mode – With the control knob turned on this
of the cylinder in which it is fitted.
mode willof
or manual
perature function. position the thermostat will control water temperature to maximum 60°C and is
ned on
mode willthis
function. OFF – Inbythis
unaffected anymode the thermostat
interruption of power supply. willUse
notthisoperate,
position foronly the double pole
manual
efunction.
safety cut
60°C and is switchingcutor by timer such as economy type installations. Antibacterial mode will function.
e
nob safety cut
turned safety out will function. Antibacterial mode will NOT function.
for manual
raturewilltoof a OFF – In this mode the thermostat will not operate, only the double pole safety cut
perature
mode function.
setting by out will function. Antibacterial mode will NOT function.
function.
perature
e safety cut of
t setting is
function. - Antifreeze
Antifreeze mode mode – This
– This setting willsetting
maintainwill maintain
a minimum wateratemperature
minimumofwater temper-
nob turned
rature
nob to a
turned
ature
20°C to of 20°Cthetowater
prevent prevent
heaterthe
fromwater
freezing.heater frommode
Antibacterial freezing. Antibacterial mode
will function.
perature of
setting
rature to bya will
MAXfunction.
– Maximum temperature in Manual Mode – With the control knob turned
function.
tsetting
settingby is clockwise to the MAX setting the thermostat will control water temperature to a
nnobaccordance
turned with the latest I.E.E. maximum of 70°C. The water temperature can be adjusted to a lower setting by
t setting is
rature to a
nection MAX
turning – theMaximum
adjustment knob anticlockwiseinupManual
temperature to 80° where
Mode the lowest
– With setting
theis control knob
r settingtoby the unit. approximately 10°C. Antibacterial modesetting
will function
ngsetting
switch is with contact separation turned clockwise to the MAX the thermostat will control water tem-
nstaccordance with the latest I.E.E.
perature to a maximum of 70°C. The water temperature can be adjusted to a
n accordance with the latest I.E.E. ELECTRICAL CONNECTIONS
e cord with a minimum T rating of
nection to the unit.
lower
1. This setting by turning
unit should the by
be connected adjustment knob electrician
a suitably qualified anticlockwise up towith
in accordance 80°the
where
latest I.E.E.
ng switch with
nection to the unit. contact separation the lowest setting
regulations. is approximately 10°C. Antibacterial mode will function.
ld result in thewith
n terminations
latestbeing
ngaccordance
switch with contact the separation
I.E.E. 2. Ensure the electrical supply is switched off before making any connection to the unit.
e cord with a minimum T rating of 3. The immersion heater must be wired through a double pole isolating switch with contact separation
enection
cord withto the unit.
a minimum T rating of of at least 3mm in both poles.
ngresult
ld switchinwith contact separation
the terminations being 4. The immersion heater must be wired with a heat resistant flexible cord with a minimum T rating of
earth post (marked “E”) using the “T-80” and with a minimum cross-section area of 1.5mm2.
ld result in the terminations being
e cord with a minimum T rating of 5. Ensure that the terminal screws are not over tightened as this could result in the terminations being
ostat terminal marked “L” broken off.
hermostat
uld result terminal marked “N”
earth postin(marked
the terminations
“E”) usingbeing
the WARNING: THIS DEVICE MUST BE EARTHED
ake proof
earth
34Earth“E”)www.jouleuk.co.uk WIRING:
post | www.joule.ie
washerpost (markedNut using the
ostat terminal marked “L” 1. Earth connection (green & yellow) should be made firmly to the earth post (marked “E”) using the
Electrical
theConnections
most efficient use of electricity. In the event of any power loss the thermostat will lose all recorded
data,should
1. This unit and will restart learning mode.
be connected byAntibacterial
a suitablymode will function.
qualified NOTE: Changing
electrician thermostat setting
in accordance with the latest
from the factory pre-set position may impact upon the efficiency rating of the cylinder in which it is fitted.
I.E.E. regulations.
OPK – Basic Electronic Thermostat mode – With the control knob turned on this
2. Ensureposition the thermostat
the electrical supplywill control water temperature
is switched off beforetomaking
maximumany
60°Cconnection
and is to the unit.
unaffected by any interruption of power supply. Use this position for manual
switching or by timer such as economy type installations. Antibacterial mode will function.
3. The immersion heater must be wired through a double pole isolating switch with contact sepa-
ration OFF – Inleast
of at this mode
3mm theinthermostat will not operate, only the double pole safety cut
both poles.
out will function. Antibacterial mode will NOT function.
4. The immersion heater
- Antifreeze modemust be wired
– This setting with aaheat
will maintain resistant
minimum flexible cord
water temperature of with a minimum T rating
20°Cand
of “T-80” to prevent
with the water heatercross-section
a minimum from freezing. Antibacterial
area of mode will function.
1.5mm2.
MAX – Maximum temperature in Manual Mode – With the control knob turned
5. Ensureclockwise
that the terminal
to the screws
MAX setting are not over
the thermostat tightened
will control as this could
water temperature to a result in the terminations
being maximum
broken off.of 70°C. The water temperature can be adjusted to a lower setting by
turning the adjustment knob anticlockwise up to 80° where the lowest setting is
approximately 10°C. Antibacterial mode will function
This device must be earthed wiring
ELECTRICAL CONNECTIONS
1. This unit should be connected by a suitably qualified electrician in accordance with the latest I.E.E.
regulations.
2. Ensure the electrical supply is switched off before making any connection to the unit.
3. The immersion heater must be wired through a double pole isolating switch with contact separation
1. Earth connection (green
of at least 3mm & yellow)
in both poles. should be made firmly to the earth post (marked “E”) using
the terminals attachments
4. The immersion heaterprovided.
must be wired with a heat resistant flexible cord with a minimum T rating of
“T-80” and with a minimum cross-section area of 1.5mm2.
2. The Live5. Supply
Ensure that the terminal
(brown) fromscrews are not over
the mains tightened
supply cable as to
thisthe
couldthermostat
result in the terminations being
terminal marked “L”
broken off.
WARNING: THIS DEVICE MUST BE EARTHED
3. The Neutral
WIRING:
connection (blue) from the mains supply cable to the thermostat terminal marked
“N” 1. Earth connection (green & yellow) should be made firmly to the earth post (marked “E”) using the
terminals attachments provided.
2. The Live Supply (brown) from the mains supply cable to the thermostat terminal marked “L”
3. The Neutral connection (blue) from the mains supply cable to the thermostat terminal marked “N”
Shake proof Earth post
Thermostat washer Nut
Over Temp. Earth cable
Safety Reset Cup washer
Square
washer Nut
Website: www.thermowatt.com
Contact: thermowattservice@thermowatt.com
5
Cold Main Hot Water Outlet
3
Balanced Cold
Connection
4 High Limit
Stat
6
Dual
Stat
10
7
Boiler Prim. Return
Secondary
Return
1 2 9 11
1 Bronze Pump
2 Non Return Valve (not supplied)
3 Inlet Control Group
4 Temperature & Pressure Relief Valve
5 Isolation Valve (not supplied)
6 Exp. Vessel with Wall Bracket
7 2-port Zone Valve (one only supplied)
9 Drain Valve (not supplied)
10 Tundish
11 Heating Circ. Pump (not supplied, required with heat only boiler)
36 www.jouleuk.co.uk | www.joule.ie
Un-Plumbed Cylinder Schematic
Electrical Diagram S-Plan
5
Cold Main Hot Water Outlet
3
Balanced Cold
Connection
4 High Limit
Stat
6
Dual
Stat
10
1 2 9 11
1 Bronze Pump
2 Non Return Valve (not supplied)
3 Inlet Control Group
4 Temperature & Pressure Relief Valve
5 Isolation Valve (not supplied)
6 Exp. Vessel with Wall Bracket
7 2-port Zone Valve
8 3-port Valve (not supplied)
9 Drain Valve (not supplied)
10 Tundish
11 Heating Circ. Pump (not supplied, required with heat only boiler)
38 www.jouleuk.co.uk | www.joule.ie
Un-Plumbed Cylinder Schematic
Electrical Diagram Y-Plan
7
01 Portable Vessel
14 02 Heating Vessel
03 Inlet Control Group
04 Temperature & Pressure Relief Valve
05 P Valve
06 Exp. Vessel With Wall Bracket
07 Tundish
15 9
08 Heating Zone 1 Valve
09 DHW Valve
10 Heating Zone 2 Valve
8 11 Automatic Bypass
12 Heating Return Flow Pipe
13 Circulation Pump
14 Filling Loop
15 3kW Immersion
12 11 16 Return Flow To Boiler
16
40 www.jouleuk.co.uk | www.joule.ie
Pre-Plumbed Cylinder Schematic
Electrical Diagram Indirect System Boiler, One Heating Zone
Pre-wired
7
01 Portable Vessel
14 02 Heating Vessel
03 Inlet Control Group
04 Temperature & Pressure Relief Valve
05 P Valve
06 Exp. Vessel With Wall Bracket
07 Tundish
15 9
08 Heating Zone 1 Valve
09 DHW Valve
10 Heating Zone 2 Valve
8 11 Automatic Bypass
12 Heating Retun Flow Pipe
10 13 Circulation Pump
14 Filling Loop
15 3kW Immersion
12 11 16 Return Flow To Boiler
16
42 www.jouleuk.co.uk | www.joule.ie
Pre-Plumbed Cylinder Schematic
Electrical Diagram Indirect System Boiler, Two Heating Zone
Pre-wired
7
01 Portable Vessel
14 02 Heating Vessel
03 Inlet Control Group
04 Temperature & Pressure Relief Valve
05 P Valve
06 Exp. Vessel With Wall Bracket
07 Tundish
15 9
08 Heating Zone 1 Valve
09 DHW Valve
13 10 Heating Zone 2 Valve
8 11 Automatic Bypass
12 Heating Return Flow Pipe
13 Circulation Pump
14 Filling Loop
15 3kW Immersion
12 11 16 Return Flow To Boiler
16
44 www.jouleuk.co.uk | www.joule.ie
Pre-Plumbed Cylinder Schematic
Electrical Diagram Indirect Heat Only Boiler, One Heating Zone
Pre-wired
7
01 Portable Vessel
14 02 Heating Vessel
03 Inlet Control Group
04 Temperature & Pressure Relief Valve
05 P Valve
06 Exp. Vessel With Wall Bracket
07 Tundish
15 9
08 Heating Zone 1 Valve
09 DHW Valve
13 10 Heating Zone 2 Valve
8 11 Automatic Bypass
12 Heating Retun Flow Pipe
10 13 Circulation Pump
14 Filling Loop
15 3kW Immersion
12 11 16 Return Flow To Boiler
16
46 www.jouleuk.co.uk | www.joule.ie
Pre-Plumbed Cylinder Schematic
Electrical Diagram Indirect Heat Only Boiler, Two Heating Zone
Pre-wired
Electrical Controls
Suitable time and temperature controls should be installed to allow the cylinder to operate at it’s
maximum efficiency. All electrical work carried out must comply with IEE Wiring Regulations (BS
3456). Products must also be installed as per the regulations in G3 of the Building Regulations. A
boiler interlock should be in place and is a wiring arrangement where the boiler cannot fire unless
there is a demand for hot water generation.
Temperature control
clockwise to increase,
Thermal cut-out counter-clockwise to
reset under cap decrease
The link must be installed between the adjustable thermostat and the safety cut-out thermostat as
shown above. The operating thermostat which controls the temperature of the domestic hot water
is adjustable. A safety cut out is also incorporated within the thermostat and will operate at 85°C ±
3°C. Both thermostats should run in series. To reset the safety cut-out and the motorised valve the
reset button must be pressed in.
Before resetting the safety cut-out or altering the thermostat setting, isolate electrical
supply to the unit before removal of the cover.
48 www.jouleuk.co.uk | www.joule.ie
Discharge Arrangement
Discharge Pipework
The inlet control group should be positioned so that the discharge from both safety valves can be
combined via a 15mm end feed tee. Connect the tundish and route the discharge pipe which must
be routed in accordance with Building Regulations - Part G3 of schedule 1.
When operating normally water will not be discharged. Water discharge from the two safety valves
will only occur under fault conditions. The tundish should be vertical, located in the same space
as the unvented hot water storage system and be fitted as close as possible, and lower than the
valve, with no more than 600mm between the safety device outlet e.g. the temperature relief valve
and the tundish.
The position of the tundish must be that when installed it is visible to the occupants of the prem-
ises. When positioning the tundish, the drain valves and motorised valve ensure that these items
are positioned away from any electrical devices. The discharge pipe (D2) coming from the tundish
should terminate in a safe place where there is no risk to persons in the vicinity of the discharge,
be of metal and:
• Be at least one pipe size larger than the nominal outlet size of the safety device unless its total
equivalent hydraulic resistance exceeds that of a straight pipe 9m long, i.e. discharge pipes
between 9m and 18m equivalent resistance length should be at least two sizes larger than the
nominal outlet size of the safety device, between 18 and 27m at least 3 sizes larger, and so on.
• Bends must be taken into account in calculating the flow resistance. Refer to diagram 1, Table 1
and the worked example. An alternative approach for sizing discharge pipes would be to follow
BS6700 Specification for design, installation, testing and maintenance of services supplying
water for domestic use within buildings and their curtilages.
• Have a vertical section of pipe at least 300mm long, below the tundish before any elbows or
bends in the pipework.
It is preferable for the discharge to be visible at both the tundish and the final point of discharge.
Where this is not possible or practically difficult, there should be clear visibility at one or other of
these locations.
Downward discharges at a low level; i.e. up to 100mm above external surfaces such as car parks,
hard standings, grassed areas etc. are acceptable providing that where children play or otherwise
come into contact with discharges, a wire cage or similar guard is positioned to prevent contact
whilst maintaining visibility.
Discharges at a high level; e.g. in to metal hopper and metal down pipe with the end of the
discharge pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high
temperature discharges of water and 3m from any plastic guttering systems that would collect such
discharges (tundish available).
Where a single pipe serves a number of discharges, such as in blocks of flats, the number served should
be limited to not more than 6 systems so that any installation can be traced reasonably easily.
The single common discharge pipe should be at least one pipe size larger than the largest indi-
vidual discharge pipe to be connected. If unvented hot water storage systems are installed where
discharges from safety devices may not be apparent, i.e. in dwellings occupied by blind, infirm or
disabled people, consideration should be given to the installation of an electronically operated de-
vice to warn when discharge takes place.
Worked Example
The example on the next page is for G1/2 temperature relief valve with a discharge pipe (D2) having
4 No. elbows and length of 7m from the tundish to the point of discharge.
Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2
temperature relief valve is: 9.0m. Subtract the resistance for 4 No. 22mm elbows at 0.8m each =
3.2m. Therefore the maximum permitted length equates to: 5.8m. 5.8m is less than the actual length
of 7m, therefore calculate the next largest size.
Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2 temperature relief
valve equates to: 14m. As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.
G 1/2 G 3/4 G1
Min. size of discharge pipe D1 15mm 22mm 28mm
50 www.jouleuk.co.uk | www.joule.ie
Safety Device
(temperature relief valve) Metal discharge pipe (D2) from
temperature relief valve to tundish
Maxim Tundish
um 6
00mm
Minimum 300mm
Discharge below fixed grating
Trapped Gulley
The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-
metallic rainwater goods may be damaged by such discharges.
Filling
First you must ensure that the pressure in the expansion vessel is the same as the setting of the
pressure reducing valve i.e. 3 bar (45PSI). The valve is of the Schrader car tyre type. Check all the
connections for water tightness including any factory made connections such as the immersion
heater and the temperature and pressure relief valve. Prior to filling, open the hot tap furthest away
from the cylinder to expel air. Open the cold main isolation valve and allow the unit to fill.
Once the cylinder has been fully commissioned it should be heated to its normal operating temper-
ature. Draw off secondary hot water to each outlet and allow hot water to flow from each outlet for
at least 30 seconds to remove any flux residue from the pipe work within the secondary hot water
system. Then fully drain the cylinder and re-fill to ensure that all flux residues are removed from the
system.
Indirect Units
Fill the primary circuit according to the boiler manufacturers’ commissioning instructions. Any addi-
tives used in the heating system water circulating through the cylinder coil must be compatible for
use with stainless steel cylinders.
Ensure the lever on the two port valve is set to the filling position. When full, move the lever back.
Switch the programmer to Domestic Hot Water (DHW) and allow the unit to start to heat. Adjust the
dial of the dual thermostat to between 30°C and 70°C as required.
Storage Temperature
60-65°C is the recommended storage temperature for both direct and indirect cylinders. In hard
water areas consideration should be given to reducing this to 50-55°C. In many healthcare appli-
cations the guidance on Legionella control and safe water delivery temperatures will require storing
the water at 60-65°C, distributing at 50- 55°C and using thermostatic mixing valves to control the
final temperature. For details consult the NHS Estates Guidance on safe hot water temperatures.
52 www.jouleuk.co.uk | www.joule.ie
Maintenance
General
Servicing should only be carried out by competent installers and any spare parts used must be
purchased from Joule™.
Never bypass any safety devices or operate the unit without them being fully operational
Draining
Switch the electrical power off (important to avoid damage to element). Isolate boiler from the unit.
Turn off the cold water supply valve. Open hot water tap. Open the drain valve. The unit will drain.
Annual Maintenance
The water heaters require annual servicing in order to ensure safe working and optimum perfor-
mance. It is essential that the following checks are performed by a competent installer on an annual
basis. This is commonly done at the same time as the annual boiler service.
• Twist the cap of the expansion relief valve on the inlet control set and allow water to flow for 5
seconds. Release and make sure it resets correctly.
• Repeat with the pressure / temperature relief valve. In both cases check that the discharge
pipework is carrying the water away adequately. If not, check for blockages etc. and clear.
• Check that any immersion heaters fitted are working correctly and that they are controlling the
water at a temperature between 55°C and 65°C.
• Check the pressure in the expansion vessel is charged to 3 bar. Turn off the water supply to the
unit and open a hot tap first. The air valve on expansion vessel is a Schrader (car tyre) type.
• Air or CO2 may be used to charge the expansion vessel. Unscrew the head on the inlet control
set and clean the mesh filter within.
The Service Checklist supplied with this unit should be updated at each service.
Your guarantee may be void if you cannot produce proof of annual servicing immer-
sion heater replacement.
Prior to installing the replacement Immersion, ensure the o-ring is correctly positioned on the head
of the Immersion and lubricate the threads before fitting.
Thread the Immersion by hand until it is hand tight and then tighten gently to allow the o-rings to
create a water tight seal.
Inspection
Where internal inspection of the cylinder is required an endoscope can be used. Inspection can be
carried out by draining down the cylinder and removing a component that is fitted to a wet connec-
tion in the cylinder.
• Check your discharge pipework is free from debris and is carrying water away to waste effec-
tively.
• Next hold both of these safety valves open, allowing as much water as possible to flow through
the tundish.
• Release the valves and check that they reseat correctly.
54 www.jouleuk.co.uk | www.joule.ie
Taking The Cylinder Out Of Use
Shutting Down
• Ensure the cold water supply is isolated and at least two hot water draw off points are open
prior to draining the cylinder.
• One of the hot water draw off points should be as close as possible to the height of cylinder in
draw off terms.
• Where applicable use the drain valve at the cold water inlet to drain the contents of the cylinder.
• Isolate the coil from the main heating system. If necessary blow out the coil prior to moving the
cylinder.
Checklist
The installer must comply with all of the installation instructions contained within this installation
manual. On completion of the initial installation and after each subsequent annual service the
Benchmark Checklist must be completed and signed by the competent person who has worked
the unit.
The purpose of Benchmark is to ensure that customers have the correct equipment for their require-
ments installed in accordance with the manufacturer’s installation instructions. The equipment must
be installed by installers who have completed an accredited competent person’s scheme and who
install, commission and service the equipment in accordance with the manufacturer’s instructions.
All installations must comply with the appropriate Building Regulations and the Benchmark Check-
list should be provide to the customer. The Benchmark Checklist can also be used to show that all
equipment is installed in accordance with the relevant Building Regulations.
Your stainless system is automatic in normal use and requires only annual servicing. You should
employ a competent installer to perform the annual servicing. Normally this is timed to coincide with
the annual boiler service.
If water is flowing from the safety valves through the tundish this indicates a fault
condition and action is needed.
If this water is hot, turn the boiler and / or the immersion heater off. Do not turn off the water until
the discharge runs cool. The discharge may also stop.
Tell them you have a fault on an unvented cylinder. We stock all the spare parts they may need and
Joule™ can be contacted via telephone numbers on back page.
56 www.jouleuk.co.uk | www.joule.ie
Fault Possible Cause Solution
Water escaping from the Compression fitting on hot - Check / remake joint sealing paste.
case unit. draw off not sealing.
Cold water at hot tops. Immersion heater not switched Check / reset.
on or cutout has triggered.
Indirect - Boiler not working. Check boiler - consult boiler manufactures’
instructions.
Indirect - motorized valve fault. Check plumbing / wiring motorized valve.
Indirect - cutout in dual stat has Check for faults in the thermostat or high limit
operated. stat and reset.
Water discharges from If continual - pressure reducing Check outlet pressure from inlet control set is
expansion relief valve valve (part of inlet control set ) 3 bar.
may not be operating correctly.
If continual - expansion relief Remove cartridge - check seat and renew if
valve seat may be damaged. necessary.
If intermittent - expansion vessel Check pressure in expansion vessel. Recharge
charge may have reduced / blad- to 3 bar if necessary. If bladder perished
der perished. replace vessel.
Unit is being back pressurized. With cylinder cold check pressure in cylinder. If
this is the same as the incoming mains pressure
then you are getting backfeed. Install a balanced
cold supply.
Water discharges from Unit has overheated - thermal Switched off power to boiler and immersion
temperature & pressure controls have failed. heaters. Leave water supply on. Wait until dis-
relief valve charge stops. Isolate water supply and replace
if faulty.
Milky / cloudy water Oxygenated Water. Water from any pressurized system will release
oxygen bubbles when flowing. The bubbles will
settle out.
No hot water flow Cold main off. Check and open stopcock.
58 www.jouleuk.co.uk | www.joule.ie
Cyclone Direct / Indirect Installation Guide 59
Service Record
It is recommended that your hot water system is serviced regularly and that the apprepriate Service Record’s completed.
Service Provider
Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manu-
facturer’s instructions.
62 www.jouleuk.co.uk | www.joule.ie
Notes
mail Kylemore Park West, Ballyfermot, Dublin 10 mail Unit 17C&D Power Road, Plantation Bus. Pk.
tel +353 (1) 623 7080 Bromborough, Wirral, CH62 3RN
fax +353 (1) 626 9337 tel +44 (0) 1513 551 094
eml info@joule.ie fax +44 (0) 1513 568 336
web www.joule.ie eml info@jouleuk.co.uk
web www.jouleuk.co.uk
Joule™ PL